Enhancing Suspension Part Reliability Through Innovative Metal Stamping Process Changes

Customer Challenge: Quality Issues with International Supplier

A leading manufacturer was sourcing a critical suspension component from an international metal stamping supplier but began experiencing significant field failures. The parts were cracking in application, creating operational disruptions, rising costs, and potential safety concerns for end users.

In addition to quality challenges, the risks associated with offshore sourcing limited the customer’s ability to respond quickly and confidently. The situation required more than a replacement supplier. It required a partner who could fully understand the problem and solve it at the root.

The HTT Approach: Partnering to Solve the Root Cause

HTT approached the opportunity as a collaborative engineering partnership. As HTT President, Neil Leland, shared, “When we partner together, we win together,” and this project is a clear example of that mindset in action.

HTT’s engineering team worked side by side with the customer’s team to evaluate the part in detail. This included material analysis, stress testing, and failure mode identification. By listening and aligning on the true performance requirements, the teams identified that stress concentrations within the original metal stamping design were causing the cracking. As HTT President Neil Leland shared, “Partnerships are really measured when challenges come up. When you listen to understand and work through those issues together, that’s where you find the win-win.”

Rather than applying a temporary fix, HTT developed a more robust and manufacturable solution. The process improvement included:

• Redesigning the part to incorporate a controlled gap during forming
  

• Introducing a MIG welding step to reinforce the structure and eliminate stress concentration points
  

• Validating the updated design through rigorous real-world testing

This design for manufacturability approach ensured the part could perform reliably while maintaining efficient production.

At the same time, the program was successfully reshored to HTT’s Wisconsin-based facility, giving the customer greater control, improved communication, and a more dependable supply chain.

Through collaborative problem solving and process innovation, the customer achieved immediate and lasting improvements. As HTT Engineer, Randy Harmeling, shared, “We partner closely with our customers to help them achieve their goals, bringing our experience to solve challenges and improve designs moving forward.”

• Enhanced Product Reliability: The redesigned component eliminated cracking and delivered consistent, dependable performance in the field

• Improved Supply Chain Stability Through Reshoring: Bringing production back domestically reduced risk, improved responsiveness, and strengthened overall supply chain confidence

• Operational Efficiency Gains: Enhanced part reliability helped minimize downtime and keep production running efficiently

• Lower Total Cost of Ownership: Improved product consistency and production efficiency reduced warranty claims and delivered meaningful cost savings

• Increased Customer Confidence: With a reliable part and a responsive partner, the customer regained trust in both product performance and supply chain execution

Key Takeaways: The Value of Partnership in Metal Stamping

This project reinforces that the best solutions come from true collaboration, not transactional manufacturing relationships.

• Partnership Drives Better Outcomes: Working together leads to faster problem identification and more effective solutions
  
  
• Design for Manufacturability Matters: Early engineering involvement improves performance and reduces risk
  
  
• Process Innovation Solves Complex Challenges: Strategic changes to forming and welding can dramatically improve durability
  
  
• Reshoring Strengthens Supply Chains: Domestic production improves lead times, communication, and reliability
  
  
• Testing Validates Success: Real-world validation ensures long-term performance and confidence

Solving Complex Metal Stamping Challenges Through Partnership

At HTT, we believe the best results come from working side by side with our customers. We bring engineering expertise, manufacturing experience, and a commitment to solving problems the right way. As Andrew Kamphuis, Business Development Representative at HTT, shared, “Our customers are looking for more than just parts. They need solutions, and we bring everything together to support them from start to finish.”

From redesigning components to reshoring production, our team focuses on delivering solutions that improve quality, reduce risk, and strengthen supply chains.

If you are dealing with part failures, quality concerns, or supplier challenges, HTT is ready to partner with you to find a better way forward.

Industries: Metal Stamping, Welding, Suspension Parts, Manufacturing, Engineering